Dimming control including an adjustable output response

ABSTRACT

The present disclosure provides improved dimming or dimmer assemblies/modules for controlling lights or loads (e.g., as part of a control or automation system). More particularly, the present disclosure provides for systems and methods for utilizing dimmer control assemblies/modules advantageously having: (i) an adjustable output response, (ii) enhanced thermal management, (iii) a voltage detector to determine amplitude and zero-crossing, and/or (iv) an estimation of power consumption for multiple loads (e.g., using a single sensor).

BACKGROUND

1. Technical Field

The present disclosure relates to dimming or dimmer assemblies/modulesfor controlling lights or loads and, more particularly, to dimmercontrol assemblies/modules having: (i) an adjustable output response,(ii) enhanced thermal management, (iii) a voltage detector to determineamplitude and zero-crossing, and/or (iv) an estimation of powerconsumption for multiple loads (e.g., using a single sensor).

2. Background Art

In general, dimming or dimmer modules/assemblies that control dimmablelights or loads are known. For example, some conventional dimmer modulesare configured and adapted to control dimmable lights/loads includingLED, incandescent and fluorescent, magnetic low-voltage, electroniclow-voltage, neon, cold cathode and/or variable speed motors. Dimmermodules are generally useful in a myriad of different environments forresidential, commercial and/or industrial applications.

In some conventional assemblies, the dimmer modules are utilized as thelighting (e.g., high-voltage lighting) and/or load control points for acentralized and/or distributed system (e.g., an automation or controlsystem). For example, lights or loads in the centralized system may bewired (e.g., home-run wired) back to a dimmer module, which may beinstalled and/or housed in an enclosure or the like. The enclosure orthe like is typically installed in a mechanical room or electricalcloset, and may also house or contain a controller/processor (e.g., anautomation system controller/processor).

In general, some of the challenges that arise when creating a dimmingmodule/product can include: (i) implementing an accurate zero-crossingdetector, (ii) producing an output that is substantially smooth as thelevel is adjusted, (iii) providing useful feedback to the user regardingthe operating conditions such as power consumption of the loads, and/or(iv) managing the heat that is generated by the dimming modules ordimming circuits.

Some dimmer modules/assemblies for alternating current (AC) loads cangenerally adjust the output level by turning on power to the load foronly a portion of each cycle of the AC supply. The turn-on timingtypically should be consistent from cycle to cycle to ensure that theoutput does not have any substantial detectable variation when set to aspecific level. In general, the timing for the turn-on is oftenreferenced to the zero-crossing point of the AC supply. In the case of alighting control, the method used to detect the zero-crossing typicallyshould be accurate enough to avoid substantial errors in the turn-onthat would cause a visibly detectable change in the output. The methodshould also be robust in the face of noise levels that are sometimescommon on the incoming AC supply.

For example, some conventional dimmer modules/assemblies detect thezero-crossing by applying some hardware filtering to the measured linefeed and then converting the AC signal to digital pulses by choosing athreshold and then toggling a signal high and low as it crosses thethreshold. The timing of the pulses is then typically measured using amicrocontroller and further processing can be done with themicrocontroller, such as, for example, compensating for delay introducedby the hardware filter, and averaging multiple measurements to create amore stable reference.

Moreover, it typically is a general requirement for high quality dimmingcontrols to provide an output (e.g., light intensity) that variessubstantially smoothly during the transition from one output setting tothe next. In general, there are three basic issues that affect thesmoothness of the dimmer output for lighting controls. First, the humaneye typically has a non-linear response to differences in lightintensity. Second, the output of some lighting loads is typically notsubstantially linear with respect to the input power. Third, the outputof some lighting loads typically does not change when being dimmed nearthe high and/or low end of the input signal.

It is noted that some new load types that are becoming common generallyhave more unusual output characteristics than in the past whencontrolled by a dimmer module/assembly. Compact-fluorescent lights (CFL)and light-emitting diodes (LED) are examples of these new load types.The output characteristics of these and other loads may have a responsethat is not able to be adequately corrected for by adding simplecurvature to the dimming control signal.

It is also noted that providing certain information about the loads thata dimmer module/assembly controls can generally be useful to the enduser. For example, some conventional dimmer modules/assemblies have beenadapted and configured to provide an estimate of the power being used bythe loads. This may be accomplished by entering the rated power for eachconnected load into the software that controls the dimmermodule/assembly. In general, this data may typically be entered based onthe actual loads that were installed when the system was commissioned.The software would then use this information along with the active dimsetting on each load to calculate an estimate of the power beingconsumed.

Furthermore, the circuits that provide dimming control of a loadtypically generate heat that should be managed so that theassembly/product generally operates at a temperature that does not reachand/or exceed the rated limits of the devices used in the circuit. Forexample, some primary heat sources are the switching semiconductors thatswitch the power to the load on and off. Depending on the capacity ofthe dimmer, the switching semiconductors may generate from a few wattsup to tens of watts or more. As an example, some conventional dimmingmodules typically require that the switching semiconductors generatearound about 16 Watts. To manage this heat, a metal heat sink may beincorporated as part of the design. The heat sink typically conductsheat away from the switching semiconductors and generally allows it tomore efficiently dissipate into the surrounding environment. Moreover,attaching the semiconductors to the heat sink typically has an effect onthe efficiency of the cooling provided by the heat sink.

For example, some various conventional methods have attached thesemiconductors to the heat sink. One common method is to usesemiconductors that mount perpendicular or vertically with respect tothe printed circuit board surface and then screw them to the heat sink.Another conventional method used is to mount the semiconductors parallelor horizontally with respect to the surface of the printed circuit boardand then attach the heat sink to the back side of the circuit board.This method typically uses an array of metal-filled holes in the circuitboard to conduct heat from the side that the semiconductor is on to theside that the heat sink is on. Additionally, commercial dimmers aretypically required by electrical code to be installed inside of anenclosure that is mounted on a wall or recessed into a wall. As such, itis generally desirable to keep the depth of the enclosure to a minimum,so multiple dimmers may be installed one above the other in a verticalenclosure. Some conventional designs utilize perforations on the frontof the enclosure so that hot air can generally escape and cool air canenter. Moreover, utilizing fans inside the enclosure is typicallyunacceptable in most installations, so the enclosure should rely mostlyon convective cooling.

Thus, despite efforts to date, a need remains for improved and efficientsystems/methods that provide for dimming or dimmer assemblies/modulesthat control lights or loads. More particularly, a need remains forimproved and efficient systems/methods that provide for dimmer controlassemblies/modules having: (i) an adjustable output response, (ii)enhanced thermal management, (iii) a voltage detector to determineamplitude and zero-crossing, and/or (iv) an estimation of powerconsumption for multiple loads (e.g., using a single sensor).

These and other inefficiencies and opportunities for improvement areaddressed and/or overcome by the systems, assemblies and methods of thepresent disclosure.

SUMMARY

The present disclosure provides an advantageous dimming or dimmerassembly/module for controlling lights or loads (e.g., as part of acontrol or automation system). In exemplary embodiments, the presentdisclosure provides for improved systems and methods for utilizingdimmer control assemblies/modules advantageously having: (i) an outputresponse that is adjustable in a customized manner, (ii) enhancedthermal management, (iii) a voltage detector and enhanced algorithms todetermine amplitude and zero-crossing, and/or (iv) an estimation ofpower consumption for multiple loads (e.g., using a single sensor).

The present disclosure provides for a control assembly including a firstload circuit, the first load circuit including a first load controldevice, a second load control device, a first current detector and afirst voltage detector, the first load control device in communicationwith a first controlled device and the second load control device incommunication with a second controlled device; a processor incommunication with the first and second load control devices, the firstcurrent detector and the first voltage detector; and a first line feedassociated with the first load circuit and in communication with thefirst and second load control devices, the first current detector andthe first voltage detector; wherein at least a portion of the first linefeed is configured to travel to and be output by the first load controldevice as a first load output to the first controlled device; andwherein at least a portion of the first line feed is configured totravel to and be output by the second load control device as a secondload output to the second controlled device.

The present disclosure also provides for a control assembly wherein theprocessor is in communication with a master controller of an automationsystem, the master controller configured and adapted to transmit commandsignals to the processor to change the status of the first and secondcontrolled devices.

The present disclosure also provides for a control assembly wherein thefirst load circuit further includes a third load control device, thethird load control device in communication with: (i) a third controlleddevice, (ii) the processor, and (iii) the first line feed; and whereinat least a portion of the first line feed is configured to travel to andbe output by the third load control device as a third load output to thethird controlled device.

The present disclosure also provides for a control assembly furtherincluding a second load circuit, the second load circuit including athird load control device, a fourth load control device, a secondcurrent detector and a second voltage detector, the third load controldevice in communication with a third controlled device and the fourthload control device in communication with a fourth controlled device;and a second line feed associated with the second load circuit and incommunication with the third and fourth load control devices, the secondcurrent detector and the second voltage detector; wherein the processoris in communication with the third and fourth load control devices, thesecond current detector and the second voltage detector; wherein atleast a portion of the second line feed is configured to travel to andbe output by the third load control device as a third load output to thethird controlled device; and wherein at least a portion of the secondline feed is configured to travel to and be output by the fourth loadcontrol device as a fourth load output to the fourth controlled device.

The present disclosure also provides for a control assembly wherein theprocessor is configured and adapted to run a calibration sequence thatturns on the first and second controlled devices separately andindividually at multiple dim levels; wherein the processor is adapted toreceive for each dim level of the first and second controlled devices:(i) a current measurement provided by the first current detector, and(ii) a voltage measurement provided by the first voltage detector; andwherein the processor is adapted to calculate and store a measurement ofthe average power consumed by the first and second controlled devices ateach dim level by utilizing the respective current and voltagemeasurements of the first and second controlled devices at each dimlevel.

The present disclosure also provides for a control assembly whereinafter the calibration is completed and the power consumptionmeasurements are stored, the processor is adapted to calculate the powerconsumption of the first and second controlled devices at the presentdim level of the first and second controlled devices by utilizing thestored measurements.

The present disclosure also provides for a control assembly wherein thecalibration sequence turns on the first and second controlled devices atmultiple dim levels from a low dim level to a high dim level. Thepresent disclosure also provides for a control assembly wherein thecalibration sequence turns on the first and second controlled devices atabout eight different dim levels, each dim level spaced substantiallyevenly apart from one another.

The present disclosure also provides for a control assembly wherein theprocessor is adapted to: (i) run a calibration sequence that turns onthe first and second controlled devices separately and individually at amaximum setting, (ii) receive a current measurement provided by thefirst current detector, and a voltage measurement provided by the firstvoltage detector for the first and second controlled devices at themaximum setting, and (iii) calculate and store a measurement of thepower consumed by the first and second controlled devices at the maximumsetting by utilizing the respective current and voltage measurements atthe maximum setting; wherein after the calibration sequence is completedand the maximum setting power consumption measurements are stored, theprocessor is further adapted to: (i) receive a current measurementprovided by the first current detector and a voltage measurementprovided by the first voltage detector for the first and secondcontrolled devices at the present dim level of the first and secondcontrolled devices, and (ii) calculate and store a measurement of thetotal average power used by both the first and second controlled devicesat the present dim level by utilizing the respective current and voltagemeasurements at the present dim level; and wherein the processor isadapted to calculate the average power drawn at the present dim level byeach individual first and second controlled device by utilizing: (i) themeasurements of the power consumed by the first and second controlleddevices at the maximum setting, (ii) the measurement of the totalaverage power used by both the first and second controlled devices atthe present dim level, and (iii) the percentage of the present dimlevel.

The present disclosure also provides for a control assembly wherein theaverage power drawn at the present dim level by each individual firstand second controlled device satisfies the equation:

${{Pload} = {{Pex} + \frac{{Pw} \times {Pd}}{Ptw}}};$wherein Pex is the percent of the present dim level multiplied by therespective measurement of the power consumed by the first or secondcontrolled device at the maximum setting; wherein Pd is the differencebetween: (i) the measurement of the total average power used by both thefirst and second controlled devices at the present dim level, and (ii)the sum of the Pex values for the first and second controlled devices;wherein Pw is the percent of the present dim level multiplied by thevalue obtained by dividing the respective measurement of the powerconsumed by the first or second controlled device at the maximum settingby the sum of the measurements of the power consumed by the first andsecond controlled devices at the maximum setting; and wherein Ptw is thesum of the Pw values for the first and second controlled devices.

The present disclosure also provides for a control assembly wherein thefirst voltage detector includes an analog-to-digital converter, theanalog-to-digital converter adapted to take a plurality of measurementsof the voltage that is present at the analog-to-digital input duringeach cycle of the first line feed; wherein the analog-to-digitalconverter is adapted to communicate the measurements to the processor,the processor adapted to group the measurements into separate groups ofmeasurements; wherein the processor is adapted to calculate the averagevoltage measurement of each group and determine if the average voltagemeasurement is positive or negative; wherein the processor is adapted toidentify and analyze together consecutive groups of voltage measurementsthat have opposite positive/negative average voltage measurement valuesto estimate the voltage zero-crossing point of the first line feed'swaveform.

The present disclosure also provides for a control assembly wherein eachgroup of voltage measurements includes about twelve consecutive voltagemeasurements, each voltage measurement of each group taken about every63 μs. The present disclosure also provides for a control assemblywherein when the processor analyzes the consecutive groups of voltagemeasurements that have opposite positive/negative average voltagemeasurement values, the processor is adapted to draw lines between pairsof individual voltage measurement points from each group to estimate thevoltage zero-crossing point of the first line feed's waveform.

The present disclosure also provides for a control assembly wherein eachgroup of voltage measurements includes about twelve consecutive voltagemeasurements; wherein the processor is adapted to draw lines betweenpairs of individual voltage measurement points from each group by firstdrawing a line between the first measurement point of the first groupand the first measurement point of the second group, then drawing a linebetween the second measurement point of the first group and the secondmeasurement point of the second group, then drawing a line between thethird measurement point of the first group and the third measurementpoint of the second group, then drawing a line between the fourthmeasurement point of the first group and the fourth measurement point ofthe second group, then drawing a line between the fifth measurementpoint of the first group and the fifth measurement point of the secondgroup, then drawing a line between the sixth measurement point of thefirst group and the sixth measurement point of the second group, thendrawing a line between the seventh measurement point of the first groupand the seventh measurement point of the second group, then drawing aline between the eighth measurement point of the first group and theeighth measurement point of the second group, then drawing a linebetween the ninth measurement point of the first group and the ninthmeasurement point of the second group, then drawing a line between thetenth measurement point of the first group and the tenth measurementpoint of the second group, then drawing a line between the eleventhmeasurement point of the first group and the eleventh measurement pointof the second group, and then drawing a line between the twelfthmeasurement point of the first group and the twelfth measurement pointof the second group.

The present disclosure also provides for a control assembly whereinafter each line has been drawn between pairs of individual voltagemeasurement points, the processor is adapted to determine the voltagezero-crossing point of each drawn line and estimate the voltagezero-crossing point of the first line feed's waveform by analyzing thevoltage zero-crossing point of each drawn line. The present disclosurealso provides for a control assembly wherein the processor analyzes themedian value of the voltage zero-crossing points of all the drawn linesto estimate the voltage zero-crossing point of the first line feed'swaveform.

The present disclosure also provides for a control assembly wherein theprocessor is in communication with the first load control device via afirst control signal line; wherein the processor is adapted to store aplurality of individual data points, each individual data point being avalue that represents the magnitude of the control signal on the firstcontrol signal line that is generated for a different dim level of thefirst controlled device; and wherein the processor is adapted tocalculate a magnitude of the control signal for a dim level of the firstcontrolled device that is positioned between two data points of theplurality of data points.

The present disclosure also provides for a control assembly wherein theindividual data points are spaced apart from one another from the lowdim level to the high dim level of the first controlled device. Thepresent disclosure also provides for a control assembly wherein theprocessor stores about thirty-three individual data points, eachindividual data point being spaced apart from one another from the lowdim level to the high dim level of the first controlled device; andwherein the first nine data points proximal to the low dim level arespaced apart from one another by about 2% of the total number of dimlevels of the first controlled device, and the remaining data points arespaced apart by about 3.5% of the total number of dim levels of thefirst controlled device.

The present disclosure also provides for a control assembly wherein thedata points are generated manually by a user. The present disclosurealso provides for a control assembly wherein the data points aregenerated by software associated with a light meter, the light meterconfigured and adapted to measure the light intensity of the firstcontrolled device at a plurality of dim levels.

The present disclosure also provides for a control assembly furtherincluding a heat sink member mounted with respect to the first andsecond load control devices, the heat sink member having a bafflemember; wherein the baffle member extends along at least a portion ofthe top surface of the heat sink member for thermal management purposes.The present disclosure also provides for a control assembly wherein thebaffle member extends substantially along the length and width of thetop surface of the heat sink member.

The present disclosure also provides for a control assembly furtherincluding a heat sink member and a printed circuit board mounted withrespect to the first and second load control devices; wherein the firstand second load control devices are each mounted substantially parallelwith respect to the surface of the printed circuit board, the first andsecond load control devices positioned between the heat sink member andthe printed circuit board. The present disclosure also provides for acontrol assembly further including a rear housing mounted with respectto the printed circuit board, the rear housing including at least onehandle member that is movably and rotationally mounted with respect tothe rear housing.

The present disclosure also provides for a method for estimating thepower consumption of multiple loads including providing a load circuit,the load circuit including a plurality of load control devices, acurrent detector and a voltage detector, each load control device incommunication with a controlled device; providing a processor incommunication with each load control device, the current detector andthe voltage detector; providing a line feed associated with the loadcircuit and in communication with each load control device, the currentdetector and the voltage detector, at least a portion of the line feedconfigured to travel to and be output by each load control device as aload output to its respective controlled device; running a calibrationsequence via the processor, the calibration sequence turning on eachcontrolled device separately and individually at multiple dim levels;providing to the processor for each dim level of each controlled device:(i) a current measurement from the current detector, and (ii) a voltagemeasurement from the voltage detector; calculating and storing, via theprocessor, a measurement of the average power consumed by eachcontrolled device at each dim level by utilizing the respective currentand voltage measurements of each controlled device at each dim level;operating each controlled device at a present dim level; and calculatingthe power consumption of each individual controlled device at thepresent dim level of each controlled device by utilizing the storedmeasurements.

The present disclosure also provides for a method for estimating thepower consumption of multiple loads including providing a load circuit,the load circuit including a plurality of load control devices, acurrent detector and a voltage detector, each load control device incommunication with a controlled device; providing a processor incommunication with each load control device, the current detector andthe voltage detector; providing a line feed associated with the loadcircuit and in communication with each load control device, the currentdetector and the voltage detector, at least a portion of the line feedconfigured to travel to and be output by each load control device as aload output to its respective controlled device; running a calibrationsequence via the processor, the calibration sequence turning on eachcontrolled device separately and individually at a maximum setting;providing to the processor for each maximum setting of each controlleddevice: (i) a current measurement from the current detector, and (ii) avoltage measurement from the voltage detector; calculating and storing,via the processor, a measurement of the power consumed by eachcontrolled device at each maximum setting by utilizing the respectivecurrent and voltage measurements of each controlled device at eachmaximum setting; operating each controlled device at a present dimlevel; providing to the processor for each present dim level of eachcontrolled device: (i) a current measurement from the current detector,and (ii) a voltage measurement from the voltage detector; calculatingand storing, via the processor, a measurement of the total average powerused by the controlled devices at the present dim level by utilizing thecurrent and voltage measurements of the controlled devices at thepresent dim level; calculating, via the processor, the average powerdrawn at the present dim level by each individual controlled device byutilizing: (i) the measurements of the power consumed by the controlleddevices at each maximum setting, (ii) the measurement of the totalaverage power used by the controlled devices at the present dim level,and (iii) the percentage of the present dim level.

The present disclosure also provides for a method for estimating thepower consumption of multiple loads wherein the average power drawn atthe present dim level by each individual controlled device satisfies theequation:

${{Pload} = {{Pex} + \frac{{Pw} \times {Pd}}{Ptw}}};$wherein Pex is the percent of the present dim level multiplied by therespective measurement of the power consumed by each controlled deviceat the maximum setting; wherein Pd is the difference between: (i) themeasurement of the total average power used by the controlled devices atthe present dim level, and (ii) the sum of the Pex values for thecontrolled devices; wherein Pw is the percent of the present dim levelmultiplied by the value obtained by dividing the respective measurementof the power consumed by each controlled device at the maximum settingby the sum of the measurements of the power consumed by the controlleddevices at the maximum setting; and wherein Ptw is the sum of the Pwvalues for the controlled devices.

The present disclosure also provides for a method for estimating thevoltage zero-crossing point of the waveform of a line feed includingproviding a load circuit, the load circuit including at least one loadcontrol device and a voltage detector, the at least one load controldevice in communication with a controlled device, and the voltagedetector including an analog-to-digital converter; providing a processorin communication with the at least one load control device and thevoltage detector; providing a line feed associated with the load circuitand in communication with the at least one load control device and thevoltage detector, at least a portion of the line feed configured totravel to and be output by the at least one load control device as aload output to its controlled device; measuring during each cycle of theline feed and via the analog-to-digital converter, a plurality ofmeasurements of the voltage that is present at the analog-to-digitalconverter input; communicating the plurality of measurements to theprocessor; grouping, via the processor, the plurality of measurementsinto separate groups of measurements; calculating, via the processor,the average voltage measurement of each group; determining, via theprocessor, if the average voltage measurement is positive or negative;identifying and analyzing together, via the processor, consecutivegroups of voltage measurements that have opposite positive/negativeaverage voltage measurement values to estimate the voltage zero-crossingpoint of the line feed's waveform.

The present disclosure also provides for a method for estimating thevoltage zero-crossing point of the waveform of a line feed wherein whenthe processor analyzes the consecutive groups of voltage measurementsthat have opposite positive/negative average voltage measurement values,the processor draws lines between pairs of individual voltagemeasurement points from each group to estimate the voltage zero-crossingpoint of the first line feed's waveform.

The present disclosure also provides for a method for generating acustom curve for a dimming signal including providing a load controldevice in communication with a controlled device; providing a processorin communication with the load control device via a control signal line;storing on the processor a plurality of individual data points, eachindividual data point being a value that represents the magnitude of thecontrol signal on the control signal line that is generated for adifferent dim level of the controlled device; and calculating, via theprocessor, the magnitude of the control signal for a dim level of thecontrolled device that is positioned between two data points of theplurality of data points.

The present disclosure also provides for a control assembly including aload circuit, the load circuit including at least one load controldevice, the at least one load control device in communication with acontrolled device; a processor in communication with the at least oneload control device; and a first line feed associated with the loadcircuit and in communication with the at least one load control device;a heat sink member mounted with respect to the at least one load controldevice, the heat sink member having a baffle member; wherein at least aportion of the line feed is configured to travel to and be output by theat least one load control device as a load output to its controlleddevice; and wherein the baffle member extends along at least a portionof the top surface of the heat sink member for thermal managementpurposes.

The present disclosure also provides for a control assembly wherein thebaffle member extends substantially along the length and width of thetop surface of the heat sink member.

The present disclosure also provides for a control assembly furtherincluding a printed circuit board mounted with respect to the at leastone load control device; wherein the at least one load control device ismounted substantially parallel with respect to the surface of theprinted circuit board, the at least one load control device positionedbetween the heat sink member and the printed circuit board.

The present disclosure also provides for a control assembly furtherincluding a rear housing mounted with respect to the printed circuitboard, the rear housing including at least one handle member that ismovably and rotationally mounted with respect to the rear housing.

Additional advantageous features, functions and applications of thedisclosed systems, assemblies and methods of the present disclosure willbe apparent from the description which follows, particularly when readin conjunction with the appended figures.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments of the present disclosure are further describedwith reference to the appended figures. It is to be noted that thevarious features and combinations of features described below andillustrated in the figures can be arranged and organized differently toresult in embodiments which are still within the spirit and scope of thepresent disclosure. To assist those of ordinary skill in the art inmaking and using the disclosed systems, assemblies and methods,reference is made to the appended figures, wherein:

FIG. 1 is a partial block diagram of an exemplary embodiment of acontrol or automation system according to the present disclosure;

FIG. 2 is a partial block diagram of an exemplary embodiment of a dimmermodule or assembly for use with the system of FIG. 1;

FIG. 3 is a partial block diagram of an exemplary embodiment of a loadcircuit of the system of FIGS. 1-2;

FIG. 4 is a partial block diagram of an exemplary embodiment of avoltage detector for use with the system of FIGS. 1-3;

FIG. 5 is a partial block diagram of an exemplary embodiment of acurrent detector for use with the system of FIGS. 1-3;

FIG. 6 is a partial block diagram of an exemplary embodiment of a loadcontrol device for use with the system of FIGS. 1-3;

FIG. 7 shows an example of what the current looks like for different dimlevels of a particular incandescent load versus a constant resistiveload;

FIG. 8 is a graph showing power consumed by the load versus dimminglevel for a resistive 65 W load and a 65 W incandescent bulb;

FIG. 9 is a graph illustrating the sequential lines method forestimating the voltage zero-crossing of a line feed, by utilizing anexemplary voltage detector of the present disclosure;

FIG. 10 is a graph illustrating an exemplary load response before andafter correction, and an exemplary dim signal corrected using alinearization value;

FIG. 11 is a graph illustrating an output of an exemplary load that hasan irregular output response;

FIG. 12 shows an exemplary linearization scheme that can compensate forloads with irregular output responses, the linearization scheme having255 dimming levels;

FIG. 13 is a partial block diagram of an exemplary embodiment of a lightmeter for use with a dimmer module/assembly according to the presentdisclosure;

FIG. 14 is a side view of an exemplary enclosure housing four controlassemblies, the control assemblies not including a baffle member;

FIG. 15 is a side view of an exemplary enclosure housing four controlassemblies, the control assemblies including a baffle member;

FIG. 16 is a side view of a heat sink, heat generating member and PCBaccording to an exemplary embodiment of the present disclosure;

FIG. 17 is a front view of a dimmer module/assembly according to anexemplary embodiment of the present disclosure;

FIG. 18 is a side cross-sectional view taken substantially along theline A-A of the dimmer module/assembly of FIG. 17;

FIG. 19 is a top view of the dimmer module/assembly of FIG. 17;

FIG. 20 is a front perspective view of the dimmer module/assembly ofFIG. 17;

FIG. 21 is a rear perspective view of the dimmer module/assembly of FIG.17;

FIG. 22 is an exploded view of the dimmer module/assembly of FIG. 17;

FIG. 23 is a partial front perspective view of the dimmermodule/assembly of FIG. 17, prior to mounting with respect to anexemplary enclosure of the present disclosure; and

FIG. 24 is a partial front perspective view of the dimmermodule/assembly and enclosure of FIG. 23, after mounting.

DETAILED DESCRIPTION

In the description which follows, like parts are marked throughout thespecification and drawings with the same reference numerals,respectively. Drawing figures are not necessarily to scale and incertain views, parts may have been exaggerated for purposes of clarity.

The present disclosure provides improved dimming or dimmerassemblies/modules for controlling lights or loads (e.g., as part of acontrol or automation system). More particularly, the present disclosureprovides for systems and methods for utilizing dimmer controlassemblies/modules advantageously having: (i) an adjustable outputresponse, (ii) enhanced thermal management, (iii) a voltage detector todetermine amplitude and zero-crossing, and/or (iv) an estimation ofpower consumption for multiple loads (e.g., using a single sensor).

Current practice provides that some of the challenges that arise whendesigning/creating a dimming module/assembly can include implementing anaccurate zero-crossing detector, producing an output that issubstantially smooth as the level is adjusted, providing useful feedbackto the user regarding the operating conditions such as power consumptionof the loads, and/or managing the heat that is generated by the dimmingmodules or dimming circuits. For example and as noted above in the caseof a lighting control, current practice provides that the turn-on timingtypically should be consistent from cycle to cycle to ensure that theoutput does not have any substantial detectable variation when set to aspecific level. As such, the method used to detect the zero-crossingtypically should be accurate enough to avoid substantial errors in theturn-on that would cause a visibly detectable change in the output.Moreover, current practice also provides that some new load typesgenerally have more unusual output characteristics than in the past whencontrolled by a dimmer module/assembly, and the output characteristicsof these and other loads may have a response that is not able to beadequately corrected for by adding simple curvature to the dimmingcontrol signal.

In general, the present disclosure provides for improved dimmer controlassemblies/modules having an adjustable output response, enhancedthermal management, a voltage detector to determine amplitude andzero-crossing, and/or an estimation of power consumption for multipleloads, thereby providing a significant commercial, operational and/ormanufacturing advantage as a result.

Referring now to the drawings, and in particular to FIG. 1, there isillustrated a partial block diagram of an exemplary embodiment of acontrol or automation system 10 according to the present disclosure. Forexample, system 10 may be a home or commercial automation/control systemor the like, although the present disclosure is not limited thereto. Asshown in FIG. 1, control or automation system 10 typically includesmaster controller 14 (e.g., a central automation controller). Ingeneral, system 10 also includes at least one control assembly 15, andmore particularly, typically includes a plurality of control assemblies15 (e.g., four control assemblies 15).

Examples of suitable control assemblies 15 include, without limitation,dimmer assemblies/modules, electrical control devices, lightingcontrols, modules, relays, HVAC controls, motor controls, windowtreatment controls, security controls, temperature controls, waterfeature controls, media controls and/or audio/video controls or thelike. It is noted that the master controller 14 may be the main centralprocessing unit (“CPU”) of the control or automation system 10, or itmay be an access point to the automation system network. As noted, anexemplary control or automation system 10 of the present disclosure isdepicted in FIG. 1. Other non-limiting exemplary control or automationsystems for use with the assemblies and methods of the presentdisclosure are explained and described in U.S. Patent Publication No.2009-0055760 to Whatcott et al., the entire contents of which is herebyincorporated by reference in its entirety.

In general, the master controller 14 may transmit command signals tocontrol assemblies 15 (e.g., to processor 12—FIG. 2) to change thestatus of a controlled device or load 17 (e.g., to dim a light, and/orto turn a light on or off, etc.). Examples of suitable controlleddevices 17 include, without limitation, lights, lighting equipment,electrical devices, loads, computers, processors, processing equipment,computing equipment, HVAC equipment, motors, shades, fans, outlets,security systems, electronics, electronic equipment, distributed audiosystems, televisions and/or audio/video equipment or the like.

The master controller 14 may receive status signals from the controlassemblies 15 regarding the status of a controlled device 17. In certainembodiments, at least one control assembly 15 includes a controllablyconductive device, such as, for example, a relay or triac, to controlpower to a controlled device 17. In general, control assemblies 15 maybe wall-box mounted or enclosure mounted. The control assemblies 15 mayinclude control points, or the control points may be separate, such as,for example, a keypad. More particularly and as shown in FIG. 1, inaddition to being in communication with at least one control assembly15, the master controller 14 may be in communication with keypads and/orstations, third-party devices, and/or additional controllers, etc.Moreover, the controller 14 may be capable of communication with anetwork/internet, and may be capable of sending/receiving audio, videoand/or data or the like.

In general and as shown in FIGS. 1-6, at least one control assembly 15of system 10 is a dimmer module/assembly 15. In exemplary embodiments,system 10 includes four dimmer modules/assemblies 15, although thepresent disclosure is not limited thereto. Rather, it is noted thatsystem 10 may include any number of dimmer modules/assemblies 15 (e.g.,one, two, three, four, a plurality, etc.). FIG. 2 shows a partial blockdiagram of an exemplary embodiment of a dimmer module/assembly 15 foruse with system 10.

In general, dimmer module/assembly 15 is configured and adapted tocontrol at least one controlled device 17 (e.g., at least one light orload). In exemplary embodiments and as discussed further below, dimmermodule/assembly 15 of system 10 is configured and adapted to control atleast twelve controlled devices 17 (e.g., at least twelve lights orloads) (FIG. 2). However, it is noted that dimmer module/assembly 15 ofsystem 10 may be configured and adapted to control any number ofcontrolled devices 17 (e.g., one controlled device, two controlleddevices, four, a plurality, etc.).

In exemplary embodiments and as shown in FIG. 2, dimmer module/assembly15 typically includes at least one processor 12. In general, processor12 is in communication with a power supply 20. Processor 12 typically isin communication with master controller 14 (e.g., wired or wireless) forcontrol purposes. For example, processor 12 may be in communication withmaster controller 14 over a communication line 13 (e.g., bus line) viainterface 19 (e.g., module bus interface 19—FIG. 2) for controlpurposes. Processor 12 may also include and/or be in communication withswitches 21 and/or indicators 22.

In general, processor 12 is in communication with (e.g., via controllines/signals) at least one load circuit 16. FIG. 3 depicts a partialblock diagram of an exemplary embodiment of a load circuit 16 of dimmermodule/assembly 15.

In exemplary embodiments, processor 12 is in communication with fourload circuits 16 (FIG. 2), although the present disclosure is notlimited thereto. Rather, processor 12 may be in communication with anysuitable number of load circuits 16. Load circuit 16 typically isassociated and/or in communication with at least one line feed or powersupply 18. With reference to FIGS. 3-5 and as discussed in furtherdetail below, load circuit 16 typically includes a voltage detector 31and a current detector 33.

In general, load circuit 16 includes at least one load output 23. Inexemplary embodiments and as shown in FIGS. 2-3, load circuit 16includes three load outputs 23 (e.g., line feed 18 has three loadoutputs 23), although the present disclosure is not limited thereto.Rather, load circuit 16 may include any suitable number of load outputs23. Load output 23 typically is in communication with a controlleddevice 17 for control purposes.

As shown in FIGS. 3 and 6, load circuit 16 includes at least one loadcontrol device 25. In exemplary embodiments and as shown in FIG. 6, loadcontrol device 25 includes a switching device 27 (e.g., a switchingsemiconductor such as a triac, etc.). Load control device 25 may alsoinclude a mechanical relay 29 or the like.

In exemplary embodiments, load circuit 16 includes three load controldevices 25, although the present disclosure is not limited thereto. Loadcircuit 16 may include any number of load control devices 25. Ingeneral, at least a portion of the line feed 18 of load circuit 16travels to load control device 25 and is output as a load output 23 byload control device 25 (e.g., to device 17). Load control device 25typically is in communication with processor 12 (e.g., via communicationlines and/or control/status signals) for control purposes (e.g., forcontrol of controlled device 17).

The present disclosure will be further described with respect to thefollowing examples; however, the scope of the disclosure is not limitedthereby.

EXAMPLE 1 Estimating Individual Load Consumption

As noted above and with reference to FIGS. 2-5, each load circuit 16 ofeach dimmer module/assembly 15 typically includes a voltage detector 31and a current detector 33. In certain embodiments and also as notedabove, each dimmer module/assembly 15 typically includes four loadcircuits 16, although the present disclosure is not limited thereto. Assuch, in exemplary embodiments, each dimmer module/assembly 15 typicallyincludes four voltage detectors 31 and four current detectors 33 (e.g.,one of each for each load circuit 16).

In other words, each load circuit 16 typically includes both a voltagedetector 31 and a current detector 33 for its respective line feed 18 toallow for, inter alia, calculation of power consumption. As noted above,each load circuit 16 typically includes three load outputs 23 (e.g.,each line feed 18 has three load outputs 23). Each load output 23typically is in communication with a load or controlled device 17 forcontrol purposes. As shown in FIG. 5, current detector/sensor 33typically includes a current sensor member or element 34 (e.g., aresistor or hall-effect sensor or the like), an amplifier 36 and afiltering member 38.

In general, the voltage input typically will be substantially the samefor each load output 23 on a line feed 18, so a single voltage detectoror sensor 31 per line feed 18 is sufficient to accurately measure thevoltage for each load output 23. However, each load output 23 on a linefeed 18 can be using a different amount of current at any given moment,so a single current detector or sensor 33 typically can provide a directmeasurement of the total current in all three load outputs 23, but noteach load output 23 individually when they are all turned on.Additionally, the current drawn by a controlled device 17 (e.g., a lightor load) attached to a load output 23 may vary depending on the type ofcontrolled device 17 (e.g., on the load type) and/or on the dim level ofthe controlled device 17. It is noted that this problem could be solvedby placing a current detector/sensor 33 or the like on each load 17, butthis would quickly add cost to the assembly 15, and/or would takeadditional board space (e.g., PCB space) that may not be available.

In exemplary embodiments of the present disclosure, dimmermodule/assembly 15 advantageously utilizes a single currentdetector/sensor 33 for each load circuit 16 to save cost and space. Itis noted that a measurement of the current drawn by each individual loadoutput is desired. In this regard, the systems, assemblies and methodsof the present disclosure advantageously utilize the information fromthe single current detector/sensor 33 to accurately calculate anestimate of the individual load 17 values. In exemplary embodiments,these systems/methods are based on the concept of calibrating each load17 by taking measurements while only one load or controlled device 17 ata time is turned on and then using this data to calculate the estimate.

For example, a purely resistive load or controlled device 17 presents afixed impedance that does not substantially vary significantly due toexternal conditions. Since the impedance is generally fixed, the amountof current that will flow through it can be calculated based on theapplied voltage. One measurement of the load output 23 current can betaken at a known voltage to determine the resistance and then thatresistance can be used to calculate the current for other voltages. Inthe case of a sinusoidal voltage, the current can be measured at onepoint in the waveform, and that measurement can be used to determine thecurrent at any other point in the waveform. The current through acontrolled device 17 that presents a fixed impedance generally has thesame amplitude at a given point in the cycle, regardless what dim levelthe device 17 is set on.

In general, one of the most common load types or controlled devices 17is an incandescent bulb. An incandescent bulb generally is a resistiveload, but the resistance typically varies significantly withtemperature. It has been found that an incandescent bulb is sensitiveenough to temperature that it will have a different resistance atdifferent dimming levels. FIG. 7 shows an example of what the currentlooks like for different dim levels of a particular incandescent loadversus a constant resistive load. In this case, taking a singlemeasurement of the current is generally not enough to allow one topredict the current at all the dim levels.

Other practical examples of loads 17 that are becoming more common aredimmable compact-fluorescent light (CFL) and light-emitting diode (LED)bulbs. In general, these bulbs use electronic ballasts that oftenpresent a distorted current waveform when dimmed. These tend to benon-sinusoidal and also typically make it difficult to predict thecurrent from a single measurement.

The following are advantageous methods to estimate the power consumed bythe individual loads 17 using a single current detector/sensor 33 inload circuit 16.

Method 1:

In exemplary embodiments, a calibration sequence is run by processor 12after the loads 17 are connected (e.g., after a load or controlleddevice 17 is connected to each load output 23 of load circuit 16). Forexample, the calibration sequence turns on each load 17 separatelyand/or individually (e.g., while all the other loads 17 are turned offor are not turned on) at multiple dim levels from low to high (e.g.,about eight different dim levels), and processor 12 then stores ameasurement of the average power consumed by each load 17 at each ofthese dim levels. At each dim level (and for each load 17 individually),the current measurements are provided by the current detector 33, andthe voltage measurements are provided by the voltage detector 31. Thecurrent and voltage measurements are then utilized by processor 12 tocalculate the average power consumed by each load 17 at each of the dimlevels.

These stored power measurements/levels then form a calibration table foreach load 17. When a load 17 is in operation, its respective stored datacan then be used (e.g., by processor 12) to calculate and/or interpolatethe power consumption of the load 17 at the actual dim level that isbeing used at the moment.

In exemplary embodiments, storing a plurality (e.g., about eight)different points/measurements of power drawn, with eachpoint/measurement being substantially evenly-spaced apart from oneanother at differing dim levels, has been found sufficient to provide avery accurate estimate of power consumption of the load 17 at the actualdim level that is being used at the moment. For the loads that weretested, the response was curved near the beginning and the end of thedim settings, and was substantially linear or straight in the middle ofthe dim settings (FIG. 8). As such, it is noted that the accuracy can beincreased by either adding more points or distributing the points sothat there are more points near the ends than in the middle of the dimsettings. FIG. 8 shows the difference between a resistive 65 W load anda 65 W incandescent bulb.

Method 2:

This method estimates the average power drawn for a single load using asingle calibration measurement for the load, the dimming level for theload, and a measurement of the total average power used by all of theloads connected to a single current detector 33 including the load forwhich power is being estimated. The calibration measurement is performedafter the loads 17 are connected. It is measured for each load output 23of circuit 16 set to a level of full on one at a time. The average powermeasurements are obtained by using the measurements from the currentdetector 33 and voltage detector 31. For reference, the average powermay be calculated by measuring the instantaneous current and voltage atmultiple (may be 12) points spaced evenly over the period of a halfcycle (for AC power); multiplying the current and voltage measurementsat each point to obtain a set of instantaneous power measurements; andthen taking the average of the instantaneous results by dividing by thenumber of points (12 in this case).

In exemplary embodiments, when the dimmer module 15 is in normaloperation, the average power for each load 17 can be estimated by anovel calculation that uses the calibration data along with the dimminglevel for each load 17 and the total average power measured for theloads 17 connected to a single current sensor 33. In general this methodprovides for a faster calibration process and requires less memorystorage on processor 12 since only one calibration calculation needs tobe made and stored for each load, and the calibration calculationtypically only requires measurements made at a single dimming level.This method, however, can be less accurate when compared to Method 1described above. The novel calculation is shown below in Equation 1.

$\begin{matrix}{{Pload} = {{Pex} + \frac{{Pw} \times {Pd}}{Ptw}}} & \underset{\_}{{Equation}\mspace{14mu} 1}\end{matrix}$

Where Pload, the result of the calculation, is the average power used byone particular load 17, and the other parameters are obtained asfollows.

Pex

This is the calculated average power that would be consumed if the loadwas a fixed resistive load dimmed at the level that the actual load iscurrently being dimmed at. It is calculated using the calibrated powermeasurement along with the dimming level using the following Equation 2:Pex=DimPercent×Pcal  Equation 2:

Where Pcal is the calibrated value that has been stored for this load asdescribed above, and DimPercent is the percentage of the available inputsignal that is being output to the load by the dimmer.

Pd

This is the difference between the total measured power (Ptm) for all ofthe loads connected to a single current detector and the sum of thevalues of Pex for each of the loads connected to that current detector.

Pw

This is a weighted value for this load calculated using the followingEquation 3:Pw=DimPercent×PcalPercent  Equation 3:

Where DimPercent is the same as described above and PcalPercent is valueof Pcal for this load divided by the sum of the values of Pcal for allthe loads connected to this current detector.

Ptw

This is the sum of the values of Pw for each of the loads connected tothis current detector.

Example Calculation:

As an example suppose there are three loads that are each dimmed at 50%connected to a single current detector. The loads are all incandescentlight bulbs where Load1 is a 300 W rated bulb, Load2 is 60 W rated bulb,and Load 3 is a 40 W rated bulb. First, we measure Pcal for each loadand get the following:Pcal1=287Pcal2=58Pcal3=39

With all the loads turned on and dimmed to 50%, we measure Ptm to be224.5.

Next, we calculate the value of Pex for each load.Pex1=0.5*287=143.5Pex2=0.5*58=29Pex3 0.5*39=19.5

Calculate Pd.Pd=Ptm−(Pex1+Pex2+Pex3)=224.5−(143.5+29+19.5)=32.5

Calculate Pw for each load.Pw1=0.5*Pcal1/(Pcal1+Pcal2+Pcal3)=0.5*287/(287+58+39)=0.374Pw2=0.5*Pcal2/(Pcal1+Pcal2+Pcal3)=0.5*58/(287+58+39)=0.076Pw3=0.5*Pcal3/(Pcal1+Pcal2+Pcal3)=0.5*39/(287+58+39)=0.051

Calculate Ptw.Ptw=Pw1+Pw2+Pw3=0.374+0.076+0.051=0.501

Then the final calculation gives the average power for each load as,Pload1=143.5+0.374*32.5/0.501=167.8Pload2=29+0.076*32.5/0.501=33.9Pload3=19.5+0.051*32.5/0.501=22.8

For comparison, the actual measured power for each load in this casewas:Pactual1=171Pactual2=35.5Pactual3=24

EXAMPLE 2 Voltage Detector to Determine Amplitude and Zero-Crossing

As noted above and with reference to FIGS. 2-5, each load circuit 16 ofeach dimmer module/assembly 15 typically includes a voltage detector 31and a current detector 33. In other words, each load circuit 16typically includes both a voltage detector 31 and a current detector 33for its respective line feed 18 to allow for, inter alia, calculation ofpower consumption. As noted above, each load circuit 16 typicallyincludes three load outputs 23 (e.g., each line feed 18 has three loadoutputs 23). Each load output 23 typically is in communication with aload or controlled device 17, e.g., a dimmable light, for controlpurposes.

In exemplary embodiments and as shown in FIGS. 3-4, voltage detector 31on line feed 18 of dimmer module/assembly 15 allows one to detect theamplitude of the voltage for a given line feed 18. It is also noted thatit is useful to determine the zero-crossing from this same voltagedetector 31. FIG. 4 is a partial block diagram of an exemplaryembodiment of a voltage detector 31 for use with the system of FIGS.1-3.

In exemplary embodiments and as shown in FIG. 4, resistors R1, R2, andR3 of voltage detector 31 operate as a voltage divider and currentlimiter 35. This allows for the use of a physically small transformer T1that is low-current and typically does not require a high primary tosecondary turns ratio for the winding. In general, the output of thetransformer T1 can be fed through a filter circuit 37 and then into ananalog-to-digital converter (ADC) 39. Next, the digital data isprocessed (e.g., via processor 12) to determine the amplitude andzero-crossing.

In exemplary embodiments, the amplitude of the voltage for a given linefeed 18 can be determined by testing the circuit to find the ratio ofthe input line feed 18 voltage to the voltage that is present at the ADC39 input. This ratio can be used as a multiplier to calculate the linefeed 18 voltage. This amplitude measurement is useful for diagnosticpurposes as well as in calculating power consumption for the line feed18.

In general, accurately detecting the voltage zero-crossing point of thepower supply's (e.g., line feed 18) waveform is useful in AC dimmingcircuits. For example, it is used to keep the dimming signalsynchronized with the alternating line feed 18 voltage. The voltagedetector 31 circuit described provides an isolated and scaled-downrepresentation of the line feed 18 voltage. In general, the ADC 39 isconfigured and adapted to take many sample measurements of the voltagethat is present at the ADC input during each cycle of the line feed 18.These sample measurements may then be broken down into groups (e.g., onegroup is 12 samples, with one sample taken about every 63 μs), and thenfurther analyzed. One exemplary process (e.g., via processor 12) is asfollows:

-   -   1) Take the average of each group of sample measurements to        determine if the average is higher or lower than zero (positive        or negative).    -   2) Continue until a group of samples has an average value that        is opposite (e.g., positive or negative) from the previous        group. For example, the previous group's average was higher than        zero and the current group's average is lower than zero.    -   3) If the group sizes are large enough (e.g., about 12 samples        per group), then a transition of the average as described in        step 2 above indicates that a zero crossing occurred within        those two groups of samples.    -   4) Analyze the individual samples in the two groups from step 2        above to determine the zero-crossing point.

One exemplary implementation configures/adapts the ADC 39 to take onesample of the voltage that is present at the ADC input about every 63μs, and uses groups of 12 samples. It has been found, after muchexperimentation and calculation, that this method provided excellentperformance without requiring too much processing time. In addition, thedirect-memory-access (“DMA”) function of the processor ormicrocontroller 12 can advantageously be utilized to transfer the samplemeasurements directly to memory storage of processor 12 to awaitprocessing via the processor 12.

Several investigations were completed for performing step 4 above(analyzing the individual samples in the two groups to determine thezero-crossing point). One successful approach was to program theprocessor 12 to draw lines between pairs of points in the sample set andinterpolate the zero-crossings for the lines. This gives a group ofzero-cross estimates that can be analyzed to choose the likelyzero-cross point. Many combinations for the pairs were attempted,including, without limitation, the following:

-   -   A) Start with the first point in a group and create pairs with        all the other points in that group, then move to the next point        of that group and continue this way all the way through the set        of points in that group. For example and with reference to FIG.        9, lines would first be drawn between point 1 and point 2, point        1 and point 3, point 1 and point 4, point 1 and point 5, and        then point 1 and point 6. Next, lines would be drawn between        point 2 and point 1, point 2 and point 3, point 2 and point 4,        point 2 and point 5, and point 2 and point 6. This method would        continue in a similar manner for points 3 through 6.    -   B) Start with the first and last points of a group and work        inward pairwise toward the middle two points of that group. For        example and with reference to FIG. 9, a line would be drawn        between point 1 and point 6, between point 2 and point 5, and        between point 3 and point 4.    -   C) The Sequential Lines Method: Using the two groups start with        the first point in each group (the first point from the first        group and the first point from the second group, or the first        point overall and the first point after the middle point        overall) and work pairwise from beginning to end of each group.        In other words and as shown in FIG. 9, lines are drawn between        points 1 and 4, 2 and 5, and 3 and 6.

As noted, Method C above is called the sequential lines method. Duringtesting, the sequential lines method performed better than the otherline-drawing methods (e.g., better than Methods A and B noted above). Anexample drawing of the sequential lines method is shown in FIG. 9,illustrated with 6 total points (3 pairs/lines of points).

After determining the zero-crossing estimate for each line drawn betweentwo points, the group of estimates can be used to determine where theactual zero-cross of the AC supply occurred. In one embodiment, theaverage of the zero-crossings of all of the drawn lines is used as theestimate of the zero-cross of the AC supply. In another embodiment, themedian of the zero-crossings of all of the drawn lines is used as theestimate of the zero-cross of the AC supply.

In exemplary embodiments, an oscilloscope can be used to measure theamount of variation between the final estimate of the zero-cross and theactual zero-cross of the signal. It has been found that taking a medianof the zero-crossings of the drawn lines, as opposed to an average,improves the accuracy of the result, e.g., there is less measuredvariation between the median and the actual zero-cross of the AC supplythan between the average and the actual zero-cross. By nature, themedian ignores situations where a single point (or small number ofpoints compared to the total number) is significantly in error.

Another investigation that was completed for performing step 4 above(analyzing the individual samples in the two groups to determine thezero-crossing point) included using a least squares calculation. Theleast squares method performed well, but it was not quite as accurate asthe sequential lines method discussed above, for the conditions tested.In one test, the least squares calculation had about 58 μs of measuredvariation compared to about 51 μs of measured variation for thesequential lines method.

EXAMPLE 3 Adjustable Output-Response Curve

As noted above, current practice provides that some new load typesgenerally have more unusual output characteristics than in the past whencontrolled by a dimmer module/assembly, and the output characteristicsof these and other loads may have a response that is not able to beadequately corrected for by adding simple curvature to the dimmingcontrol signal.

For example, to generally provide high quality dimming, some dimmermodules have incorporated therein a trim and/or linearization value. Thetrim value typically allows the dimming range to be adjusted so that thedimming signal stays out of areas near the high and/or low end (e.g.,areas that typically do not change the output). If the lighting loadnormally does not turn on until the control signal level is increasedbeyond about 10%, then the trim value can generally be set to about 10%on the low end. This typically causes the control signal to start fromabout 10% as the lowest dim setting, and then all other dimming stepsare typically divided up between about 10% and about 100%, instead ofthe original 0% to 100%.

In general, the linearization value allows the control signal to beadjusted so that it varies in a non-linear fashion. This typicallyallows the output to be adjusted to try to match a substantially smoothresponse for the human eye. Some manufacturers use a method that causesthe linearization value to adjust the control signal by introducing someamount of curvature to its output over the dimming range. In general,increasing and decreasing the linearization value affects how extremethe curvature is. On some dimmer assemblies/products, about ten datapoints are taken from the desired curve and programmed into the dimmersby the main controller. This typically keeps the storage space for thecurve data fairly low, but generally means that the resolution of theactual curve used by the dimmers may be limited. To help with this, moreof the data points may be located near the beginning and end of thecurve where more detail is often required with common load types. See,e.g., FIG. 10.

However, some new load types have more unusual output characteristicsthan in the past when controlled by a dimmer module/assembly. Forexample, these include compact-fluorescent lights (CFL) andlight-emitting diodes (LED). The output characteristics of these andother loads may have a response that is not able to be adequatelycorrected for by adding simple curvature to the dimming control signal,as some have accomplished with a linearization value. Moreover, theresponse may also vary to an extent that about ten data points is nolonger generally sufficient to describe a curve to correct it. Forexample, the output of such a load may look like that as shown in FIG.11.

In exemplary embodiments, the present disclosure provides for a newlinearization scheme that can compensate for loads with irregular outputresponses. In one embodiment, a table of about thirty-three (33) datapoints is utilized to describe the shape of the dimming control signalas it varies from low to high (dim level). It has advantageously beenfound that having about this many data points (e.g., about thirty-three)gives one the resolution to compensate for very extreme load responses.

In exemplary embodiments, about the first nine or so data points may bepositioned/measured closer together as compared to the remainder of thedata points, in order to provide extra precision on the low end. It isnoted that more data points (greater than about 33 data points) can beutilized if desired, although adding more data points to thelinearization scheme adds additional storage on the dimmermodule/assembly 15 (e.g., on processor 12), and/or on system 10 (e.g.,on master controller 14).

In exemplary embodiments, each data point is a 16-bit value thatrepresents the magnitude of the control signal that should be generatedfor the dim level corresponding to that data point. In general, thedimmer module/assembly 15 utilizes interpolation (e.g., via processor12) to estimate the desired control signal output for dim levels thatfall between the data points.

FIG. 12 shows an exemplary linearization scheme that can compensate forloads with irregular output responses, the linearization scheme having255 dimming levels. In one embodiment and as shown in FIG. 12, the firstnine data points are spaced apart by about 2% of the total number ofdimming levels and the remaining data points are spaced apart by about3.5% of the total number of dimming levels. In this embodiment, thefirst nine points are spaced about five dim level steps apart, and theremaining points are spaced about nine dim level steps apart.

It is noted that one can still use these data points to describe asimple curved correction, but now a user can also create a table of datapoints to describe a more complex curve that can be used to correct aload that provides an arbitrary response. For example, this table ofdata points can be generated manually by viewing the appropriate outputof a load (e.g., intensity of a light), manually adjusting the valuesstored in the relevant table(s) in the controller software, and thenchecking the result.

Another option is to automate the process of generating thelinearization data for a load 17 (e.g., a light fixture) using software24 to control a light meter 11 and a dimmer module/assembly 15, as shownin FIG. 13. Software 24 is typically utilized by a separate processor orthe like (e.g., separate from processor 12). However, it is noted thatmaster controller 14 may utilize software 24 as discussed below.

In exemplary embodiments, the process has two basic steps. First, thesoftware 24 gathers data about the output response of the light fixture17. Second, the software 24 compares this data to the desired responseand generates a linearization table that will achieve the desiredresponse.

The first step of gathering the data can be accomplished by setting thedimmer output to multiple levels from 0% to 100%. The output signal ofthe dimmer in this case should be linear as it is varied. At each dimlevel, the software 24 stores a measurement of the light intensity takenby the light meter 11. This provides the software 24 with the responseof the light fixture 17 to a linear drive signal.

The second step of generating the linearization data is accomplished byfirst choosing a desired response (e.g., a desired light intensity).Then, the data for the measured response of the fixture 17 gathered inthe first step is compared to the desired response. The software 24checks the high and low end of the measured response to see if anytrimming is required. The first and last points of the linearizationtable are set based on any trimming that is required. The remainingpoints are generated to compensate for any differences between thedesired output and the measured output. For example, if the measuredvalue at a particular point is higher than the desired output, then thelinearization value for that point is set to output a dimming signalthat is lower than what was used when the measurement was taken.

For example, this setup can be used in a lab or the like to generatelinearization tables for various loads 17, and these tables can be keptin a library and/or database (e.g., electronic database). The librarycould then be shared with installers. This method could also be used bythe installer themselves by providing them with the hardware andsoftware required to take the measurements. This would allow theinstaller to tune the response of the load 17 during commissioning ofthe system 10.

Thus, the above disclosure describes another option for generating anon-linear curve for the dimming signal that provides a smooth, linearor near-linear transition in the load output (e.g., light intensity) byinputting the linearization values into the software (e.g., intoprocessor 12 and/or master controller 14). Currently, a user can enter asingle parameter (e.g., an integer from 1 to 100) that the software theninputs into a mathematical function to produce a set table of datapoints that define the curve. The present disclosure describes a novelalternative by which a user can create a custom table of data pointsthat define a curve that is more detailed in its shape. The singleparameter option is advantageously simple and quick and allows foradequate correction to be applied in many cases. The custom table methodadvantageously allows for finer control and correction of irregular loadoutputs.

EXAMPLE 4 Thermal Management

In general, the present disclosure provides for improved dimmer controlassemblies/modules having enhanced thermal management. In exemplaryembodiments, the present disclosure provides for systems/methods forimproving the power-handling capability of multiple dimming modules 15mounted in an enclosure (e.g., a vertical enclosure) by enhancing theperformance of the thermal management.

As noted above and as depicted in FIGS. 14-15, control assemblies 15(e.g., dimmer modules/assemblies 15) may be mounted/housed at leastpartially within an enclosure 41. FIG. 14 depicts four controlassemblies 15 mounted within vertical enclosure 41. It is noted thatenclosure 41 may house/contain any number of control assemblies 15and/or master controllers 14 of system 10 (e.g., one, two, four, aplurality, etc.).

As shown in FIG. 14, each control assembly 15 does not include a bafflemember 43. As such, at least some of the hot/warm air (depicted byarrows H) generated from the lower assemblies 15 rises substantiallydirectly from the lower assemblies 15 to the upper assemblies 15, andgenerally decreases the cooling efficiency of the heat sinks 47 on theupper assemblies 15.

In certain embodiments and as shown in FIG. 15, each control assembly 15(e.g., dimmer module/assembly 15) housed within enclosure 41 includes atleast one baffle member 43. In general, each control assembly 15includes one baffle member 43, although the present disclosure is notlimited thereto.

As best shown in FIGS. 19, 20 and 22, baffle member 43 typically extendsalong at least a portion of the top surface of heat sink 47 of controlassembly 15. In exemplary embodiments, baffle member 43 extendssubstantially along the length and width of the top surface of heat sink47 of control assembly 15 for thermal management purposes. In exemplaryembodiments, baffle member 43 is mounted with respect to rear enclosureor housing 53 of the assembly 15 (e.g., to the top surface of rearhousing 53 via fastening members 57 or screws, etc.—FIG. 22).

In general, the convection cooling performance of the enclosure 41 isimproved (FIG. 15) by adding baffle member 43 to at least one controlassembly 15 (e.g., to the top surface of heat sink 47). It has beenfound that baffle member 43 advantageously creates turbulence in therising hot air from/in the heat sink 47 and directs at least some of therising hot air out through the front of the enclosure 41. Moreparticularly and as depicted in FIG. 15, at least some of the heatgenerated by the lower assemblies 15 is diverted out the front of theenclosure 41 and away from the upper assemblies by baffle members 43. Inexemplary embodiments and as shown in FIG. 15, each assembly 15 inenclosure 41 includes a baffle member 43 for improved thermal managementpurposes.

As shown in FIGS. 16 and 22, the present disclosure also provides forimproved systems and methods for mounting a heat generating member 27′(e.g., a switching semiconductor 27′) with respect to the heat sink 47and PCB 49 of assembly 15. As noted above, previous mounting techniquesrequired additional mounting space between the heat sink and the PCBthat caused the heat sink to be smaller, and/or required heat to betransferred from the heat generating member and through the printedcircuit board (PCB) before being transferred to the heat sink.

The present disclosure advantageously provides a system/method formounting the heat generating member 27′ (e.g., a switching semiconductor27′) substantially parallel or horizontally with respect to the surfaceof the PCB 49 facing the heat sink 47 (and facing the front of enclosure41), with the rear side of the heat generating member 27′ substantiallyfacing the heat sink 47.

In one embodiment and as shown in FIGS. 16 and 22, the heat generatingmember 27′ is a switching semiconductor or the like, and the leads 51 ofthe semiconductor 27′ are configured and dimensioned so that they extendtoward the front side of the semiconductor 27′ and touch at least aportion of the PCB 49, where they then can be fastened or soldered tothe PCB 49. As shown in FIGS. 16 and 22, this thereby advantageouslypositions and/or sandwiches the semiconductor 27′ between the PCB 49 andthe heat sink 47 (see also FIG. 18).

In general, the rear housing 53 of the assembly 15 includes at least onesupporting member 55 (FIG. 22). In exemplary embodiments, housing 53includes two supporting members 55, each supporting member 55 extendingfrom the bottom side to the top side of housing 53. Supporting member 55may be a presser board or presser bar or the like that isformed/fabricated into or mounted with respect to housing 53.

Fastening members 57 (e.g., screws or the like) are typically attachedthrough the rear enclosure 53 (e.g., through each supporting member 55),and then through the printed circuit board 49, and then into the heatsink 47. When the members 57 are tightened, the rear housing 53 (e.g.,each supporting member 55) presses on/against the printed circuit board49 and holds the at least one semiconductor 27′ tightly to or proximalthe heat sink 47. This thereby provides for an excellent thermaltransfer from the at least one semiconductor 27′ to the heat sink 47.Also, the heat sink 47 can be made as large as possible, because themembers 27′ are not mounted perpendicular or vertically with respect tothe surface of the PCB that faces the heat sink 47, which would restrictthe size of the heat sink 47.

With reference to FIGS. 19-24, assembly 15 also typically includes atleast one handle member 59. In exemplary embodiments, assembly 15includes two handle members 59, each handle member 59 configured anddimensioned to be mounted with respect to a first or second side of thehousing 53 via at least one securing member 61 of the first and secondside of housing 53. In one embodiment, each side of housing 53 includestwo securing members 61 that are configured and dimensioned to allowhandle member 59 to be releasably and movably (e.g., rotationally)mounted with respect to each side of housing 53 (FIGS. 20, 22 and 23).

Each handle member 59 typically includes at least one receiving feature63 (e.g., an aperture or recess) that is configured to mount withrespect to a securing member 61 (e.g., a pin member or protrusion) ofhousing 53. In exemplary embodiments, each handle member 59 alsoincludes at least one engaging member 73 (e.g., an engaging member 73that includes a ridged/raised and/or recessed portion) that isconfigured and dimensioned to releasably fasten or secure to (e.g., in asnap-fit manner) at least one corresponding engaging member 75 (e.g., anengaging member 75 that includes a ridged/raised and/or recessedportion) of housing 53, to releasably secure the handle member 59 to thehousing 53 (e.g., when assembly 15 is inserted into and/or mounted withrespect to enclosure 41).

For example, each handle member 59 may include a top and bottomreceiving feature 63 that mounts/mates with respect to a securing member61, thereby releasably and movably mounting each handle member 59 to aside of housing 53. Mounted handle members 59 may then advantageously berotated, pivoted, moved or swung about each side of housing 53 viasecuring members 61 (e.g., for mounting purposes to enclosure 41). Inthis regard, each handle member 59 typically includes at least onelatching member 65 (e.g., two members 65 for each handle member 59),with each latching member 65 configured to latch or mount with respectto a corresponding mating member 67 of enclosure 41 to facilitatemounting assembly 15 to enclosure 41.

Moreover, rear housing 53 also typically includes at least one extendingmember 69 (e.g., four members 69) that extend from the rear of housing53, each extending member 69 configured to mate or mount with respect toa corresponding receiving member 71 of enclosure 41 to facilitatemounting assembly 15 to enclosure 41.

Although the systems, assemblies and methods of the present disclosurehave been described with reference to exemplary embodiments thereof, thepresent disclosure is not limited to such exemplary embodiments and/orimplementations. Rather, the systems, assemblies and methods of thepresent disclosure are susceptible to many implementations andapplications, as will be readily apparent to persons skilled in the artfrom the disclosure hereof. The present disclosure expressly encompassessuch modifications, enhancements and/or variations of the disclosedembodiments. Since many changes could be made in the above constructionand many widely different embodiments of this disclosure could be madewithout departing from the scope thereof, it is intended that all mattercontained in the drawings and specification shall be interpreted asillustrative and not in a limiting sense. Additional modifications,changes, and substitutions are intended in the foregoing disclosure.Accordingly, it is appropriate that the appended claims be construedbroadly and in a manner consistent with the scope of the disclosure.

What is claimed is:
 1. A control assembly comprising: a first loadcircuit, the first load circuit including a first load control device,the first load control device in communication with a first controlleddevice; a processor in communication with the first load control device;and a first line feed associated with the first load circuit and incommunication with the first load control device; wherein at least aportion of the first line feed is configured to travel to and be outputby the first load control device as a first load output to the firstcontrolled device; wherein the processor is in communication with thefirst load control device via a first control signal line; wherein theprocessor is adapted to store a plurality of individual data points,each individual data point being a value that represents the magnitudeof a control signal on the first control signal line that is generatedfor a different dim level of the first controlled device; wherein theindividual data points are spaced apart from one another from a low dimlevel to a high dim level of the first controlled device; wherein theprocessor is adapted to determine a magnitude of a first control signalfor a first dim level of the first controlled device that is positionedbetween first and second data points of the plurality of data points,the first and second data points adjacent to one another from the lowdim level to the high dim level; wherein the processor is adapted todetermine a magnitude of a second control signal for a second dim levelof the first controlled device that is positioned between third andfourth data points of the plurality of data points, the third and fourthdata points adjacent to one another from the low dim level to the highdim level; wherein the first controlled device has a non-linearrelationship between power delivered to the first controlled device andthe light intensity of the first controlled device when power isdelivered to the first controlled device at each individual data pointfrom the low dim level to the high dim level; and wherein the firstcontrolled device has a linear transition in light intensity between thefirst dim level and the second dim level.
 2. The assembly of claim 1,wherein the processor stores about thirty-three individual data points,each individual data point being spaced apart from one another from thelow dim level to the high dim level of the first controlled device; andwherein the first nine data points proximal to the low dim level arespaced apart from one another by about 2% of the total number of dimlevels of the first controlled device, and the remaining data points arespaced apart by about 3.5% of the total number of dim levels of thefirst controlled device.
 3. The assembly of claim 1, wherein the datapoints are generated manually by a user.
 4. The assembly of claim 1,wherein the data points are generated by software associated with alight meter, the light meter configured and adapted to measure the lightintensity of the first controlled device at a plurality of dim levels.